Basis :

Zur Strassen formula for theora

Q = 2.22Al2O3+6.48 MgO+7.6

Constituent Name

Al2O3
MgO
CaO
H2O
SiO2
Fe2O3

Heat requirement for 1 ton of cl

Calorific value of indonesian Coal

Calorific value of south african Coal

Total Coal used

Indonesian Coal
South African Coal

Coal

Indonesian
South African

Duct Dimensions
PH cyclone top outlet dia
 calciner cyclone top outlet dia
Alkali Bypass Duct

Ac

item preheater outlet

Temp. ( C ) 212
diameter (m) 1.7
Density (kg/m3) 0.7165546392
Pitot tube constant 0.73
Diifrential pressure (mmWC) 24.925
Gas velocity (m/sec) 19.0706409273
Volumentric flowrate (m3/sec) 43.3197236921
Volumentric flowrate (m3/hr) 155951.005291428

Total volumetric flowrate (m3/hr) 489530.810744135

Air inlet by pr
Blower 1
velocity readings (m/sec) 2.81
Area (m2) 0.75
volumetric flowrate (m3/sec) 2.0158333333
volumetric flowrate (m3/hr) 7257

Blower 2
velocity readings (m/sec) 3.02
Area (m2) 0.75
volumetric flowrate (m3/sec) 2.1975
volumetric flowrate (m3/hr) 7911

Net outlet volumetric

flowrate(m3/hr) 474362.810744135

Excess hot Air (m3/hr) 399716.359443386

Average temp. ( C ) 328.3333333333
Atmospheric temp. ( C ) 35
Air density (kg/m3) 0.591
Heat capacity (kJ/(kg K)) 1.052

Heat used to heat excess air (KJ/hr) 72898159.1329069

Heat used to heat excess air
(KCal/hr) 17439750.9887337
Excess heat used per ton of clinker
(kCal) 191837.260876071

Excess Heat requirement for 1 ton of clinker

Calorific value of indonesian Coal

Calorific value of south african Coal

Total Excess Coal used

Indonesian Coal
South African Coal

Price of indonesian Coal 4031

Price of South African Coal 3994

Financial Losses due to excess coal 150.5337008914

consumption

NOTE : system specific ABP air cannot be minimized so by eliminating ABP hot air

Net outlet Excess Air (m3/hr) 377504.238966341

Average temp. ( C ) 336
Atmospheric temp. ( C ) 35
Air density (kg/m3) 0.591
Heat capacity (kJ/(kg K)) 1.052

Heat used to heat excess air (KJ/hr) 70646646.1158073

Heat used to heat excess air
(KCal/hr) 16901111.5109587
Excess heat used per ton of clinker
(kCal) 185912.226620546

Excess Heat requirement for 1 ton of clinker

Calorific value of indonesian Coal

Calorific value of south african Coal

Total Excess Coal used

Indonesian Coal
South African Coal

Price of indonesian Coal 4031

Price of South African Coal 3994
Financial Losses due to excess coal 143.9689460469
consumption
 Basis : 1 Ton of clinker
ssen formula for theoratical Heat consumption per Kg of Clinker
= 2.22Al2O3+6.48 MgO+7.646CaO+5.86H2O+5.11 SiO2+0.59Fe2O3
Heat
Constituent % Multiplication Factor Consumption Net
Kcal/Kg
6.3 2.22 13.986 532.906
1.3 6.48 8.424
66 7.646 504.636
1 5.86 5.86
21.4 5.11 109.354 111.183
3.1 0.59 1.829
99.1 421.723 kcal/kg

equirement for 1 ton of clinker 421723 kcal

fraction in
mix
an Coal 4810 kcal/kg 0.54
rican Coal 5735 kcal/kg 0.46

Coal used 80.5506637379 kg per ton of clinker

43.4973584185 kg per ton of clinker
37.0533053195 kg per ton of clinker

Calculation for 1 ton of clinker

Coal %C wt of C in gm Mol of C mol of O2

83.54 36337.693222806 3028.141 3028.141

74.51 27608.417793525 2300.701 2300.701

%excess of O2 : 5% at PH outlet

Theoretical Exhaust Air 821110.96430823 litres

Feed per hr 150 ton clinker

Theoretical Exhaust Air for above

74646.451300748 m3/hr
mentioned feed

mensions
1700 mm
 2100 mm
800 mm

Actual outlet air calculation by field readings

calciner outlet ABP take of

460 313
2.1 0.8
0.4741186903 0.593052901
0.73 0.73
28.2333333333 8.5333333333
24.9522608242 12.2654927359
86.4910236044 6.1700334658 2599.183 5189.461
311367.68497566 22212.1204770454

Air inlet by preheater air lift blowers

2.69 2.6 2.88 2.89 2.6

2.66 2.75 4.45 3.1 2.6

PH outlet Calciner Outlet ABP

117002.70614316 263888.56369659 18825.089603635
212 460 313
35 35 35
0.73 0.47 0.591
1.052 1.052 1.052

15904051.483117 55452751.1095104 3253756.6494263

3804797.0055304 13266208.3994044 778410.68168093

 41852.767060835 145928.292393448 8562.5174984902 196343.6

linker 196343.576952774 kcal

fraction in mix
4810 kcal/kg 0.54
5735 kcal/kg 0.46

37.5023544939 kg per ton of clinker

20.2512714267 kg per ton of clinker
17.2510830672 kg per ton of clinker

per ton
per ton

per ton of
clinker

by eliminating ABP hot air.

PH outlet Calciner Outlet
117002.70614316 263888.56369659
212 460
35 35
0.73 0.47
1.052 1.052

15904051.483117 55452751.1095104

3804797.0055304 13266208.3994044

41852.767060835 145928.292393448

linker 187781.059454283 kcal

fraction in mix
4810 kcal/kg 0.54
5735 kcal/kg 0.46

35.86688176 kg per ton of clinker

19.3681161504 kg per ton of clinker
16.4987656096 kg per ton of clinker

per ton
per ton
 per ton of
clinker
Total Mole of total mole volume of volume of
Oxygen of air air (litres) air (m3)

5328.84258 25496.8545 624672.9 624.6729

821.110964 m3/ton of clinker

90.9090909 ton
 diffrential
pressure Avg
24.3
25.6
PH 24.925
23.7
26.1
26.1
Calciner
30.1 28.23333
top
28.5
370.202008 9.8
7.3
ABP 8.533333

8.5

2.92 2.3 2.5

2.49 2.6 2.7